Inert gas shielded magnetic field controlled electric arc metal working apparatus



May 15, 1956 L. CURT ET AL 2,745,93%

J. INERT GAS SHI ED MAGN IC FIELD CONTROLLED ELECTRIC METAL WORKING APPARATUS Original Filed Oct. 27, 1950 2 Sheets-Sheet 1 IN] 'E .V TOR S JOHN L. CURTIN DONALD M. YENNI A TTOR NE 1' May 15. 1956 J. 1.. CURTIN ET AL 2,745,934

INERT GAS SHIELDED MAGNETIC FIELD CONTROLLED ELECTRIC ARC METAL WORKING APPARATUS Original Filed Oct. 27, 1950 2 Sheets-Sheet 2 INVENTORS JOHN L. CURTIN DONALD M. YENNI MM/L 0? /d\.

ATTORNEY United States Patent INERT i GAS SHIELDED MAGNETIC" FIELD: CON- TROLLED ELECTRIC ARC METAL WORKING APPARATUS John. L. Curtin, Kenmore, andDoualdM; Yenni,-Williamsville,,N. Y., assignors,.by mesne.-assignmcnts,.to Union-Carbide and Carbon Corporation, a corporation of New York Original application October 27 {1950, Serial No: 192,482,

now Patent No.2,666 ,-122', dated January 12, 1954. and this application April 30,1953, Serial No.

8 Claims. (Cl. '219'-S) Thisdnventionrelates to metal workingwithan electrrc afc energiZed' by'cUrrent flowing through a. circuit which includes the work and an electrode,.and more particularly such metal workingin which the electrode. and the" work are protected from oxidationby'astream' of monatomic gas flowing around the are.

This application-is a division of our application Serial No;*l92,482, filed October'27, 1950.

In gas shielded-arc welding it has beengenerally found I possible-toweldstainless'steel at higher speeds by shield- 1 ingthe arc with helium without producingundercufting thanhas been the-case with argon. Howeverythere is a distinctlygreater tendency toward weld porositywith helium'unless' extremely pure helium is used. Prior to theinvention it'was' possible to produce smooth butt welds showing good penetration on eighteen-gauge sheet at speeds up to fifty inches per minute in helium,- while argon welds made at such speed'showed serious undercutting.

In an attempt'to-overcome such difiiculties, a'trialusing an elec'fromagnet consisting of a-current carrying solenoid r surrounding'thewelding electrode did not yield improved field associated with the cup did not exert directional control of the are, but changed the shape and potential gradient--in-theare. improvement inwsurfacequality or Weldingspeed was obtained withzsuch cup on-thin stainless steeh.

It alsohas been: proposed to use a' relatively ilarge 'magnee-having pole-pieces located onopposite sides -of-the gas cuppbut the inducedrmagnetic fieldafrom the arc cur- I rent caused demagnetization of :the permanent magnet by opposing. its natural fieldu. Furthermore; it iwas diificultitox use such -device between-clamps and in .other'confinedi spaces. Also. results were erratic andtunpredictable.

The main object of this .invention therefore,is.to.pno. vide an improved means for working metal with an arc shielded "from the atmosphere .in a stream. of 'monatomic gas -especially argon. Another important. object is to increase the speed-of weldingmetalincluding stainless steel. A further objectis to provide. an .improvedgas cup or nozzle. for this purpose. Additionalobjects are.to.-re-

duce the cost, increase the usefulness, and advancetheart of 'monatomic gas shielded arc weldingand cutting. Other objects will appear from the following, description.

Broadly 'accordingio the invention, there is provided a pro'cess of -W0rking metal which comprises establishing ,a metal fusi'ngelectric are between the work and'either a fusible or a refractory-metal electrode by flowing cur- Weld-beadtests showed that norent through such electrode and the work. A stream of inert gas is discharged from a cup surrounding, the electrode so that such gas flows around such electrode and arc, and over the adjacent work metal. The are is.directed with the transverse component of an auxiliary magnetic field derived from a source of flux, such as a permanent magnet, incorporated in or with the nozzle of, such cup so that the curvature of the magnet substantially coincides with that of the cup; and such work and the electrode are relatively moved along the line .to be worked, thereby progressively fusing the work metal along such line. The strength of said field is such, with respect to the current flowing in the arc, that the arc is kept'focussed on the work along such line at a substantially constant acute angle of lead or lag, whereby the speedof such relative movement is substantially increased over the prior art without. adversely affecting the quality'of the resulting product. Such angle of lead or lag is the angle between a line tangent to the are (the tangent atthe midpoint for a curved arc) and the centerline of the electrode lying in a plane containing the electrodeand the path of movement ofthe electrode with respect to the work.

A remarkable increase is attained in the maximum speed of welding thin stainless steel with helium 'aswell as with. argon'shielding by the use of such auxiliary mag netic field. The magnetic field, forexample, increases the maximum welding speed of O.050-inch thick stainless steel with D. C. straight polarity (electrodenegative) from 30 to inches per minute with argon shielding, and from 50 to inches per'minute with'helium-shielding.

One of the most noticeable results of the magnetic'fild of the invention is its influence onarc position. Optimum welding results and thermal efficiency in butt welding are produced with the auxiliary magnetic field-when the arc is focussed forwardly in the directionof-=weld travel at a lead angle of about 45 degrees to-the work, without any lateral deviation to right or left of-theweldihg-line.

A marked increase in the speedof arc cuttingmetal sheet, and cuts of improved quality'are'also secured'by theinvention.

In the drawings:

Fig: 1 is a view mainlyin'side elevation of-a-machine welding set-up illustrating the invention, parts of'the apparatus being broken away and shown in section;

Fig. 2 is' a bottom plan view of the-'torch'-'shown in Fig. l;

FigrZa. is asimilarview of a modification (oval cup);

Fig. 3 is an enlarged diagram illustrating the flux field of Fig;:2 using -D...C..-S. -P. and looking upwardly from the bottom of the torch;

Fig; 4 is: a vertical cross-sectional view of a cup modification inwhich the magnet is adjustable;

Fig. 5 is a'bottom plan view of the cup shown in Fig. 4;

Fig. 6 is another modification of the cup; and

Fig. 7 is a. bottom plan view of the latter.

As shown-in Figs. l and 2, a machine welding torch 10 is mounted above work 12 for movement along a line tobeewelded. The torch comprisesa gas-.cup,-or nozzle 14 of novel constructionsurroundinga refractory metal (tungsten) electrode 16. The electrode, is, of course, composed of fusible metal forxmetal-arc weliding. The interior of the cup is radially spacedfrom the electrode to provide an annular passage 18 .through which astream of inert gas is discharged, protectingtheheated parts of the electrode and work, aswelltassthe arc:20, from. the atmosphere. The work and: the electroderare connected .in a conventional arc-welding; current supply circuit (not shown), which is .wellknownto thoseskilled in the art.

. 3 i The body of the cup 14 is first made of suitable material such as drawn copper and a semi-circular end portion thereof is removed. This provides a suitable recess for securing a similarly shaped permanent horseshoe magnet 22 composed of a magnetized high-permeability alloy, which is silver-soldered in place to the body of the cup so that the axis of curvature of the magnet substantially coincides with that of the cup. A novel magnetic gas cup results which is interchangeable with conventional gas cups. The cup is preferably mounted on the torch so: that the magnet 22 is in a leading .net, instead of opposing it for D. C.S. P. welding.

When magnetic cups of the type shown (Fig. l) are used, adjustment of arc deviation from the line of travel can only be achieved by rotating the entire torch. As shown in Figs. 4-7, however, cups 24 and 26 are con- ;structed to facilitate adjustment of the arc deviation or angular position independently of the torch position. One (Figs. 4 and 5), comprises a relatively large, re-

.movable semi-cylindrical magnet 28 held in place by magnetic attraction to a soft iron ring 30 fastened near the top of the gas cup 24 (composed of copper) and creating the desired field at the arc position with downwardly and inwardly inclined steel pole pieces 32, 32,

which are welded (silver-soldered) to the poles of such magnet. The ring 30 likewise is welded to the cup at the junction of the nozzle 34 with the shoulder 36. While such construction locates the magnet away from the heated zone (thereby increasing its life), and permits instant rotary adjustment or removal of the magnet unit if desired, the magnetic field is more easily influenced ,by surrounding magnetic objects than that from the small magnet built in the gas cup, as shown in Fig. l.

The other modification, Figs. 6 and 7, comprises a small semi-cylindrical horseshoe magnet 38 welded (silvet-soldered) to the nozzle 40 near the cup tip, and

-makes use of a seat and retaining nut 42 to permit rotary adjustment of the entire cup 26 including the magnet in the torch. Hand tightness of the retaining nut 42 is sufi'icient to prevent argon or helium gas leaks and to secure satisfactory heat transfer with well-machined parts.

jected on a plane parallel with the workpiece, i. e., horizontal in normal welding. The other components have little significance and wide variations in them have little efiect on the arc direction.

A plot of the resultant magnetic field associated with butt welding 16 gauge stainless steel at inches per minute with 290 amperes, is shown in Fig. 3. The field induced by the welding current has the shape of concentric circles surrounding the arc. Direction of the resultant magnetic flux lines is indicated and the length of the arrow is proportional to the horizontal component of the field intensity in that plane. Actual meas' urements of the magnetic field from the auxiliary magnet were plotted and superpositioned on the field from the current to obtain a resultant field showing fairly good agreement with the measured resultant field. By utilizing the motor rule or the cross product of the current and field vectors, the final position of the are can be approximated.

A study was made of the effect of magnetically-defiected arcs in argon on the quantity of heat received by stainless steel workpieces and on the geometry of the resulting weld bead cross-sections as a function of the angle of inclination of the arc. The auxiliary magnetic field intensity at the electrode tip (produced by a small symmetrically-positioned horseshoe magnet) was varied from 5 to 110 gausses by changing the vertical distance between the plane of the magnet and the work surface. It was thus possible to secure calorimetric and weld bead contour measurements at arc deflections ranging from a positive angle of approximately 85 degrees are lead to a negative angle of approximately 90 degrees arc lag using 200 amperes D. C.-S. P., are current. The indicated angles of inclination were those observed in the plane containing the electrode axis and the center line of the weld bead. As viewed in the direction of travel the arc was maintained along the electrode axis normal to the work surface. The welding torch was held fixed while the Work passed beneath the -inch diameter electrode at a speed of about 114 inches per minute, using an argon flow rate of 7.1 liters per minute.

The data presented below summarize the results of measurements obtained at seven different are angles including that characteristic of normal behavior without magnetic control. It is apparent that the amount of heat received by the work and the arc efi'iciency factors reached a maximum when a suitable magnetic field was used to effect a leading angle of about 45 degrees be- The Influence of the magnetic field on the arc can be 50 tween ar nd r Heat Melted Melted Horizontal Arc Power to Bead Bead Arc Iuclination- Field, 9 Power, Wor Transfer jfl gj f fj Depth, Width, Gausses g Watts Watts Peres SQJLL Inches Inches 13. 9 2, 780 1, 640 59 0. 0007 1. 7 0.011 0.08 25 13. 1 2, 620 1, 860 71 0. 0008 2. 1 0. 011 0. 09 None 12. 8 2, 560 1, 980 77 0.0012 3. 2 0. 020 0. 11 5 12. 5 2, 500 2, 020 81 0. 0014 3.8 0. 021 0. 12 35 12. 6 2, 520 2, 000 79 0.0016 4. 3 0.021 0.12 12.9 2, 580 2, 110 82 0. 0017 4. 5 0.021 0.11 85 Lead 12.6 2, 520 1,860 74 0.0013 3. 5 0.021 0.11

predicted from the familiar electrical engineering motor rule relating the directions of magnetic field, arc current and force acting on the arc. The arc deflection agrees with the prediction based on measurements of the field resulting from the auxiliary magnet, and the self-induced field from the welding current. This field is a vector sum of the individual fields modified by external magnetic influences such as iron clamps or rollcm (which are likely to have little effect if a magnet suificiently close to the welding zone is used). The important component of the magnetic field is that proa final check.

A remarkable improvement in welding speed was attained on 0.050 inch thick stainless steel sheet by the invention. Results are summarized in the data tabulated below, and show that an increase in maximum mg 0.003 inch.

Auxiliary Weldin g Arc Arc b g ilfgff Speed, Current, Power, Remarks Gausses P. M. Amp. Watts Argon Not uscd 30 90 990 Limited by undercut. Helium do.- 50 110 1,760 Limited by low center. Argon- 100 130 425 5,0 Do. Helium... 100 190 460 6,900 Limited by sensitivity of are. Do 100 150 340 5,050 Equal power. Do. 100 170 42 6,300 Equal current.

Normal Magnetic Field Arc Welding Welding Welding elm Shielding Gas Speed, rent Amps. 33? Crown, z Crown,

Inches Inches lnchs Inches 20 360 0.004 0.000 0.001 0.006 30 470 0.020 0.024 0.005 0.005 25 320 0.004 0.005 0.005 0.004 Helium 40 480 0.004 0.011 0.002 0.006

1 Shielding gas fiow rates were 7 liters per minute for argon and 14 liters per minute for helium.

Horizontal component of magnetic field at the electrode tip was 20 30 gausses.

The magnetic field intensity required for welding 0.050 inch thick stainless steel is considerably stronger than that used on the /32-l1'1Ch steel, being 100 and 20 gausses at the electrode tip, respectively. The lower welding speed used on the -inch material may be at least partially responsible for the reduction required in the auxiliary magnetic field strength.

Fortunately, the attainment of marked improvement in welding speed does not require precise adjustment of magnetic field strength or orientation. It was found that fields varying in strength of the horizontal component at the electrode tip between 60 to 100 gausses were almost equally eifective on 0.050 inch thick stainless steel. Nevertheless, it is apparent that changes must be made in magnetic strength to achieve satisfactory results at widely varying welding speeds on materials of various thicknesses. While sufficient data were not obtained to permit tabulation of the most desirable magnetic field for different welding conditions, it is felt that two or three cups with horizontal components of field strength varying from 20 to 100 gausses at the electrode tip should take care of most down-hand welding requirements on stainless steel.

The effectiveness of magnetic arc control in increasing the maximum acceptable welding speed with argon shielding suggested its use in improving cutting performance; the cutting action being secured by rotating the auxiliary magnet approximately 180 degrees from the position employed in welding. A number of tests showed 6 that a definite improvement in' cuttirrg performance-and increased 'cuttin'g speed' -could be attinedbmlig-ineh material witli an auxiliary field 'of roughly 60 gauss'es prodiicing one -smooth -edge-and one rough edge." The smooth edge can be'='pre'determined. Typical-results are shown below:

The influence of auxiliary magnetic fields was also studied briefly on copper, Everdur, and steel. The results indicated that the invention increased the speed and reduced undercut in welding such metals with both helium and argon as the shielding gas.

It has also been found that a field such as has been described improves the performance of inert gas shielded arc Welding using a consumable metal electrode. For example, direct current-reverse polarity welding of mild steel with an argon shielded, steel electrode increased the bead width and decreased undesirably sharp intersections of the bead with the base metal. In such case the polarity of the magnet was reversed compared to straight polarity welding.

While round cups have been shown, an oval cup 44, Fig. 2, may be used without departing from the invention. In some cases oval cups are even preferred, because they have the added advantages of good gas shielding and the cup is not damaged by the lagging or leading arc.

We claim:

1. A gas cup for inert gas shielded electric arc-metal working torches, consisting of a gas nozzle having incorporated therewith a horseshoe magnet the curvature of which substantially coincides with that of the nozzle.

2. A gas cup for inert gas shielded electric arc-metal working torches, consisting of a gas nozzle having incorporated therewith a semi-circular permanent magnet the longitudinal axis of curvature of which substantially coincides with that of the nozzle.

3. A gas cup for an inert gas shielded electric aremetal working torch, consisting of a gas nozzle having a recess in the gas outlet portion thereof, and a permanent magnet mounted in such recess, said magnet having a curvature substantially similar to that of the nozzle.

4. A gas cup for an inert gas shielded electric arcmetal working torch, consisting of a gas nozzle having a semi-cylindrical recess in the gas outlet portion thereof, and a semi-cylindrical permanent magnet mounted in such recess.

5. A gas cup for an inert gas shielded electric arcmetal working torch, consisting of a gas nozzle joining a cylindrical shoulder, a ring composed of soft iron mounted at the juncture of said shoulder and nozzle, and a magnet-unit consisting of a permanent magnet fitting said nozzle adjacent said ring, said magnet having a curvature substantially similar to that of the nozzle and a pair of steel pole pieces mounted on the poles of said magnet and depending downwardly and inwardly toward the gas outlet end of said nozzle, said magnet-unit being held in place on the nozzle by the magnetic attraction of the soft iron ring, which however permits rotary adjustment of the magnet-unit on the nozzle, as well as quick removal of such unit therefrom.

6. A gas cup for an inert gas shielded electric arcmetal working torch, consisting of a gas nozzle joining a cylindrical shoulder, a ring composed of soft iron mounted at the juncture of said shoulder and nozzle, and a magnet-unit consisting of a semi-cylindrical permanent magnet fitting said nozzle adjacent said ring, and a pair of steel pole pieces mounted on the poles of said magnet and depending downwardly and inwardly toward the gas outlet end of said nozzle, said magnet-unit being held in place on the nozzle by the magnetic attraction of the soft iron ring, which however permits rotary adjustment of the magnet-unit on the nozzle, as well as quick removal of such unit therefrom.

7. A gas cup for an inert gas shielded electric aremetal working torch, comprising a nozzle having an external annular shoulder, a hollow nut engaging said shoulder for securing the nozzle in place on a torch, and a permanent magnet mounted on said nozzle between said nut and the gas outlet end of the nozzle said magnet having a curvature substantially similar to that of the nozzle.

8. A gas cup for an inert gas shielded electric aremetal working torch, comprising a nozzle having an external annular shoulder, a hollow nut engaging said shoul: der for securing the nozzle in place on a torch, and a semi-cylindrical permanent magnet mounted on said nozzle between said nut and the gas outlet end of the nozzle.

Weed Dec. 17, 1929 Gibson July 5, 1949 

1. A GAS CUP FOR INERT GAS SHIELDED ELECTRIC ARC-METAL WORKING TORCHES, CONSISTING OF A GAS NOZZLE HAVING INCORPORATED THEREWITH A HORSESHOE MAGNET THE CURVATURE OF WHICH SUBSTANTIALLY COINCIDES WITH THAT OF THE NOZZLE. 